DE102020127172A1 - Electric disc motor for driving a rim - Google Patents

Abstract

A disc motor is presented. It has a stator and a rotor. Electromagnets of the stator are curved and act simultaneously on two permanent magnets of the rotor, which are at an angle to each other. The rotor has a rotor disc that has a plurality of permanent magnets. In addition, the inside of a tube section on the periphery of the rotor disk also has a plurality of permanent magnets. Due to the basic shape, disc motors can be manufactured with rotors on the inside and rotors on the outside.

Description

The invention relates to an electric disk motor suitable for operation directly in a rim of a vehicle.

The increasing e-mobility of society on the basis of electrically operated vehicles - for example in automobile construction, motorcycle construction, e-bikes, e-scooters etc. - is constantly increasing. As a result, the demands on the electric drives are also increasing. So far, the focus has been on central electric drives that act on one or more axles via a gearbox. These powertrains are based on classic combustion engine-based drive concepts. However, they do not always offer an optimal weight/performance ratio. Electric motors that are integrated directly on or in individual driven wheels have so far been the exception. This is partly due to the previous design and the limited efficiency of the constructions used.

For example, the document describes DE 10 2014 111 234 A1 a pancake motor with at least one stator, which has at least one electrical stator winding and stator teeth, which form a tooth neck made of a soft magnetic powder composite. In addition, there is at least one disk-shaped rotor that has permanent-magnetic poles formed exclusively by ferrite magnets, at least for generating torque. Although this pancake motor has a relatively compact design, it is only partially convincing in terms of the torque provided.

There is therefore a need for a compact disc motor that can develop higher torque than traditional disc motors.

This invention is therefore based on the object of presenting a disc motor that meets both the requirements in terms of compactness and high torque.

Brief description of the invention

The above object is solved by the subject matter of the independent patent claims. Advantageous embodiments of the present invention are described by the dependent claims.

According to a first aspect, an electric disc motor suitable for operation in a rim of a vehicle is presented.

The electric disk motor has a first rotor and a first stator ring. The first rotor has a rotor ring, which in turn has a first annular surface and a parallel opposite second annular surface, each of which extends perpendicularly to an imaginary axis of rotation which runs through a center point of the rotor ring.

The rotor ring also has a first plurality of permanent magnets regularly arranged in a circular path in respective segments of a circle, which extend through the rotor ring from the first surface towards the second surface. In this case, a north-south alignment of the permanent magnets of the first plurality runs parallel to the imaginary axis of rotation and respectively adjacent permanent magnets have north-south alignments rotated by 180° with respect to one another.

The rotor ring further includes a first tubular portion extending from an outer periphery of the rotor ring concentrically with the imaginary axis of rotation away from the first annular surface. In this case, the first pipe section has a second plurality of permanent magnets arranged regularly on an inner side of the first pipe section, the first plurality being numerically the same as the second plurality. A north-south orientation of the permanent magnets of the second plurality runs perpendicular to the imaginary axis of rotation, and adjacent permanent magnets of the second plurality each have north-south orientations rotated by 180° with respect to one another. In each case different poles of the corresponding permanent magnets of the first plurality and the second plurality in the respective circular segment are at a predefined angle to one another. The angle can be 90° or more, e.g. up to about 135°.

The disc electric motor further includes a first stator ring having a first annular surface and a parallel opposing second annular surface each extending perpendicular to an imaginary axis of rotation passing through a center point of the first stator ring and the rotor. The imaginary axes of rotation of the first stator ring and those of the rotor are identical.

The stator ring further includes a third plurality of electromagnets within the first stator ring, the third plurality being fewer in number than the first plurality. The electromagnets have a curved core, for example curved by 90° or more. Normal vectors on the poles can have an angle to each other that corresponds to the predefined angle.

One pole of one of the respective electromagnets points toward an outer peripheral periphery of the first stator ring and a corresponding other pole of the respective electromagnet points toward the first surface of the first stator ring.

In the disc electric motor, there is a first gap between the respective poles of the electromagnets pointing to the periphery of the stator ring and the second plurality of permanent magnets on an inner side of the first tube section of the rotor. In addition, there is a second gap between the poles of the electromagnets pointing towards the first surface and the first plurality of permanent magnets which is opposed to a plane of the corresponding poles of the electromagnets. Thus, the rotor can rotate freely in relation to the stator ring - for example on one axis. This is also elegantly possible because the vertical and horizontal magnetic currents center and stabilize the rotor. The result is a smooth and stable run.

The disc motor presented has a number of technical effects and advantages and improvements: Compared to traditional disc motors, which usually have horizontally aligned electromagnets in the stator, the concept presented here of the curved cores and windings of the electromagnets of the stator can increase the efficiency of the Disc motor can be increased significantly. This is because, even though only one stator and one rotor element are used, an electromagnet of the stator can simultaneously act on two permanent magnets of the rotor that are arranged at an angle to each other. In principle, it is possible to achieve twice the power density, i.e. twice the torque, compared to disc motors of the same size and otherwise comparable. This also improves the ratio of manufacturing costs to the torque achieved.

According to another aspect, simpler permanent magnets can be used in comparison to conventional pancake motors, which may also do without expensive rare earths, but also only have a low magnetization. This is due to the fact that, compared to conventional concepts, there is twice the number of magnets and the electromagnets can simultaneously generate torque both via their respective north pole and via their respective south pole. This can have a significant impact on the economy of the disc motor presented.

The basis of the proposed design also provides other advantages such as efficient cooling by the air vanes on the insides of the rotor - particularly on the first surface of the rotor disk and the inside of the tube section extending away from the rotor disk and over the stator.

In contrast to conventional pancake motors, the concept presented here is characterized by its improved starting behavior. The additional orientation of the vertical magnets makes starting easier as they are aligned in the direction of rotation. Conventional pancake motors are therefore equipped with Hall sensors for good control, which can be omitted here. Hall sensors have a limited lifetime and can be sensitive to temperature. This problem is safely circumvented.

The additional magnet alignment also improves possible recuperation behavior if the disk motor is used as a generator during braking processes. In addition, conventional vehicles can be retrofitted with the concept presented here with the presented construction, if a corresponding rim is also used. In this way, normal vehicles with internal combustion engines could be converted into hybrid vehicles.

Further exemplary embodiments of the electric disc motor are described below:

According to a more advanced embodiment, the disc electric motor may also include a spacer tube portion extending between the electromagnet and an inner diameter of the first stator ring concentrically away from the first surface of the stator ring. There may also be a second stator ring concentrically attached to the spacer tube section parallel to the first stator ring. In this case, the second stator ring may have a structure corresponding to the first stator ring, and the first surface of the first stator ring may be opposite to the first surface of the second stator ring. The rotor ring can lie between the two first surfaces. The second stator ring would therefore be a mirror image of the first.

Furthermore, there can be a second tube section which extends concentrically and symmetrically to the first tube section from the second surface of the rotor and has corresponding permanent magnets. The pole orientations of the permanent magnets on the inside of the first pipe section and the inside of the second pipe section can be the same Alternate circle segments, ie NSNSNS-....

In addition, there may be a third gap between the respective poles of the electromagnets pointing to the periphery of the second stator ring and the plurality of permanent magnets on the inside of the second tubular section of the rotor. In addition, a fourth gap may exist between the first surface-facing poles of the electromagnets of the second stator ring and the first plurality of permanent magnets that is opposed to a plane of the poles of the electromagnets of the second stator ring such that the rotor is free to rotate with respect to the stator rings .

In this embodiment, the rotor, which actually consists of left and right halves but which are firmly connected to one another, can rotate between the two stator elements which are spaced apart by the spacer tube section (internal rotor).

According to a further exemplary embodiment of the electric disk motor, it has a first pivot bearing on an outside of the spacer tube section for receiving an inside of the side of the rotor pointing towards the axis of rotation. At this point, for example, a roller bearing—or one or more ball bearings—can be provided on the spacer tube section, so that the rotor is rotatably mounted on the spacer tube section.

According to an alternative further developed exemplary embodiment of the electric disc motor, this can additionally have a second stator ring which has a structure identical to the first stator, the first and the second stator ring being firmly connected to one another via their second surfaces. There can be a connecting ring between the two or the two second surfaces are connected directly to one another. In addition, the two stator rings could also be connected to one another via webs so that air can flow between them, which would be good for additional heat dissipation. In principle, however, the two stator rings should be arranged as mirror images of one another, so that the cores of the electromagnets each point outwards into the respective first surfaces.

In addition, this alternative, further developed exemplary embodiment can have a second rotor which has a structure identical to that of the first rotor, with a peripheral end of the respective first tube section of the first rotor and of the second rotor being firmly connected to one another, so that a resulting composite of the first rotor and the second rotor, the first stator and the second stator in an outer area, in which the two first pipe sections are connected to one another and enclose the stator rings in the area of their periphery.

In this case, the stator or the two halves of the stator would lie within the two halves of the rotor, which are firmly connected to one another and thus form a unit (rotor running on the outside). It is assumed that the terms “stator ring” and “stator” can be used synonymously.

According to an additional exemplary embodiment of the electric disc motor, the rotor ring can additionally have first air blades on a surface of the rotor ring that faces the imaginary center point of the rotor ring. These can ensure good internal ventilation of the electric disc motor and thus protect it from overheating.

According to a further supplementary exemplary embodiment of the electric disc motor, the rotor ring can have second air vanes adjacent to or between the permanent magnets of the first plurality, which extend away from the first surface of the rotor ring within the first gap. These can also provide additional good internal ventilation of the electric disc motor, so that as much of the hot air that can form between the gaps in the disc motor is transported out of the disc motor.

According to a practical embodiment of the electric disk motor, a second pivot bearing - for example as a roller or double ball bearing - can be present on the inside of the tubular section, the second pivot bearing being adapted to receive a hub rotatably mounted in the second pivot bearing. This hub can, for example, belong to a wheel rim of a vehicle. The hub could then be firmly connected to a brake disc present on the vehicle.

According to an advantageous exemplary embodiment of the electric disk motor, the ratio of the third plurality to the first plurality can be as 3 to 4. This would mean that the number of permanent magnets in the rotor would be higher than the number of electromagnets in the stator. For example, there could be 28 permanent magnets in the rotor while there would only be 21 electromagnets in the stator. This ratio has been found to be practical for the operation of the electric disk motor. However, other plural ratios are also possible.

According to a further advantageous exemplary embodiment of the electric disc motor, the first stator ring can have electrical connections, for example three connections, on its second surface, for example, which are connected to selected ones of the electromagnets via electrical connections running inside the first stator ring, so that, for example, each third electromagnet can be activated at the same time. In this case, a known method for the effective electrical connection of the electromagnets and a corresponding control among one another can be used.

According to an additional exemplary embodiment of the electric disc motor, the spacer tube section can have insulated vias which selectively connect the electrical connections located in the first stator ring and the second stator ring to one another. For this purpose, for example, plug-in connections can be provided on the spacer tube section and in the surfaces of the stator rings. In this way, there would be no exposed electrical wires within the electric disc motor. Nevertheless, a modular structure would be possible.

According to a practical embodiment of the electric disk motor, the first and/or the second stator ring can be made of aluminum, steel, plastic including carbon material or other composite materials, in which the coils (with the cores) of the electromagnets and insulated electrical connections can be embedded. For example, the electromagnets could be fixed on one of their sides with their respective cores on a given surface. The respective supporting material of the respective stator could then be cast around the electromagnets. It is also possible to manufacture the supporting parts of the stator and rotor using a 3D printing process. In any case, the stator should consist of a material of sufficient quality to be able to withstand the forces that occur and at the same time to be able to dissipate waste heat well. In contrast, the rotor parts can be dimensioned to be lightweight since they can be additionally stabilized by the rim potentially lying around them. However, it is also necessary for the rotors that the connection to the respective magnets - e.g. glued on or embedded - is stable in order to prevent the magnets from detaching from the surfaces of the rotors.

According to a further developed embodiment of the electric disc motor, there can be a fastening element which extends away from one of the surfaces of the stator ring, the outer contact point of which on the stator ring should have a smaller distance from the axis of rotation than an inner diameter of a rotor ring, and the inner contact point on the stator ring has a greater distance to the axis of rotation than the inner diameter of a rotor ring. The fastening element could thus be connected completely to the respective second surface of the stator ring.

In addition, the fastening element can be designed in such a way that it is suitable for being connected firmly or detachably to an element of a vehicle—for example the brake caliper. The brake caliper could have a corresponding receiving device.

Accordingly and according to a further advantageous embodiment of the electric disc motor, the fastening element can be suitable for engaging in a groove, a lug or a bore of a brake caliper, whereby rotation of the stator or stators relative to the brake caliper is prevented. Alternatively, other elements on a respective axle of a vehicle can also be used to prevent the stator from rotating during active operation. In addition, the electrical connections could be connected to corresponding connections on the brake caliper or another connection point of the respective axle of the vehicle through or via the fastening element. By routing the electrical connections within the fastening element, no exposed electrical cables would be present at this point either.

By simply pushing or piercing the fastening element into a corresponding groove in the brake caliper, a wheel can be changed using the conventional method. It would also be conceivable that the rims were delivered complete with the disc motors. The respective motor would only have to be connected to the vehicle electrics/electronics via a plug.

According to a particular embodiment, the fastener may extend perpendicularly away from one of the surfaces of the stator ring. Alternatively, fastening elements are also conceivable, which extend away from the surface of the starter ring at predefined angles. "Extend perpendicularly" does not necessarily mean "parallel to the axis of rotation". The fastening element should always be designed in such a way that the greatest possible torque can be transmitted between the stator and the brake caliper - or another stationary part of a vehicle. Structural features of the vehicle can also play a role here.

According to a practical embodiment of the electric disc motor, it can have a third pivot bearing - for example in the form of a roller bearing or double ball bearing - on a side of the first rotor ring facing the axis of rotation, the third pivot bearing being adapted to accommodate a hub rotatably mounted in the third pivot bearing . For example, the hub may be associated with a rim, which is typically threadably attached to a member of a brake disc. This would create a firm connection between the rim and the brake disc. The disc motor would be between the hub and an inside of the rim portion that houses the tire.

Correspondingly and according to a further exemplary embodiment of the electric disk motor, the hub can therefore be a hub of a rim. Alternatively, the hub can be an axisymmetric extension of a brake disc oriented towards the stator. In both cases, the effect of driving the rim can be achieved by the disc motor.

According to a further practical embodiment of the electric disk motor, a radial surface of a respective first tube section may have one or more grooves or lugs (e.g. parallel to the axis of rotation) which may be adapted to engage in corresponding lugs and grooves of a rim inner side. The disc motor would thus be located inside the rim, with the rim being guided with the hub through the center of the disc motor and the outer periphery of the rotor(s) engaging in corresponding elements (lugs, grooves, etc.) of the rim.

According to an additional embodiment of the electric disk motor, respective cores and/or coils of the respective electromagnets should be flush with the surfaces to which they abut. This ensures that parts of the electromagnets do not protrude beyond the surfaces from which they emerge. In this way it becomes possible to ensure the narrowest possible gaps between the moving parts, thanks to which high efficiency of the disc motor is achieved.

According to a further supplementary exemplary embodiment of the electric disc motor, the fastening element can be adapted to accommodate electrical connections of the respective stator and make them connectable to a vehicle. The electrical connections of the electromagnets of the stator(s) can be routed inside the fastening element. The electrical connections can be in the form of plugs (or sockets) and can be connected via the fastening element to a counterpart on the vehicle (socket/plug)—for example on the brake caliper—for power transmission. This means that the disc motor can be easily removed from both the rim and the brake disc without an additional screw connection after removing the rim.

It is pointed out that embodiments of the invention have been described with reference to different objects of the invention. In particular, some embodiments of the invention may have been described with apparatus claims and other embodiments of the invention with method claims. However, it will be immediately clear to those skilled in the art upon reading this application that, unless explicitly stated otherwise, any combination of features belonging to one type of subject matter of the invention is also possible, in addition to any combination of features belonging to different types of objects of the invention.

Further advantages and features of the present invention result from the following exemplary description of currently preferred embodiments. The individual figures of the drawings of this application are to be regarded as schematic only and are not true to scale.

character list

• 1 represents a basic form of disc motor with a rotor ring and a stator ring that are separated from each other.
• 2 shows a sectional view through a stator with a curved electromagnet.
• 3 represents the assembled disc motor.
• 4 Figure 1 shows a half section through the assembled disc motor 3 represent.
• 5 shows the stator together with a spacer tube section.
• 6 shows a combination of the two stators, which are connected to one another by the spacer tube section.
• 7 Figure 1 shows the expanded rotor with a second tube section extending concentrically and symmetrically to the first tube section from the second surface of the rotor.
• 8th shows an assembled disc motor consisting of the double stator according to 6 and according to the rotor 7 .
• 9 shows a half section through stators according to an embodiment.
• 10 shows two adjacent stators.
• 11 shows a view of an embodiment with a rotor part of an outer rotor.
• 12 Fig. 12 shows an embodiment of the disk motor with an external rotor
• 13 13 shows a half section 1300 of the embodiment of the disc motor with an outer rotor according to FIG 12 .
• 14 shows an example of air vanes on the inside of a rotor.
• 15 . shows a detailed illustration for air blades.
• 16 shows a disk motor, the rotor of which has an example of toothing on its outside.
• 17 shows the disc motor according to 16 installed in a rim in half-section view.
• 18 shows a disc motor with fastener and a separate caliper/disc combination.
• 19 shows a fastener snapped onto a brake caliper.

Detailed description of exemplary embodiments

The following terms and expressions are used in this document:

The term "rotor" describes the rotatable part of an electric motor. In the basic form of the disk motor presented here, the rotor essentially has the shape of a disk that is equipped with permanent magnets. In addition, the rotor has an axisymmetric extension on the periphery of the rotor disk, which extends away from the rotor disk and can also be equipped with permanent magnets on its inside.

The term "wheel rim of a vehicle" describes a tire-bearing part of a vehicle, e.g. a car, a van or a truck. Bicycles (e-bikes), e-scooters or e-motorcycles are also conceivable. The rim is typically connected to a rotatable part on the vehicle which is journalled in or on the wheel suspension via the hub of the rim. The disc motor can be located inside and surrounded by the rim. The inside of the rim can accommodate the rotor with a precise fit. Gearing can ensure that power transmission or torque transmission can take place from the disc motor to the rim.

The term “rotor ring” describes the inner part of a disc motor rotor. It can have a first and a second surface. Permanent magnets can be embedded in the surface of the rotor ring at regular intervals or regular segments of a circle. The orientation of the permanent magnets alternates between adjacent permanent magnets.

The term "permanent magnet" describes an element made of a ferromagnetic material. The material of the permanent magnets used in the disc motor presented should have a high permanent magnetization, as is the case with hard magnetic materials made of alloys of iron, cobalt, nickel, ferrites and other rare earths.

The term "pipe section" describes a part of a pipe whose cut surfaces are essentially perpendicular to the longitudinal symmetry of the pipe. The length of the pipe section can be smaller than its diameter.

The term "stator ring" - short for stator - describes a basic element of a stator of the disc motor. In contrast to the rotor, the stator is fixed. The stator ring can accommodate the curved electromagnets so that poles of the electromagnets point to the periphery of the stator ring on the one hand and to a side surface or a first surface of the stator ring on the other hand. The material of the stator ring can be, for example, aluminum or an alloy containing aluminum or carbon composites. The stator ring should also have the ability to dissipate heat. Material combinations are also conceivable, in which the electromagnets are inserted into larger openings in the stator disk and then cast in with a composite material.

The term "spacer tube section" describes a tube section that can be used to space two stators or stator disks. It can also have bores or threads with which the stator discs can be attached to the spacer tube section. In addition, electrical lines insulated by the material of the spacer tube section can be routed from one stator disk to the other and thus selectively electrically connect the electromagnets.

The term “electromagnet” here describes an electromagnet with a special geometric design. The core of the electromagnet is not stretched linearly but follows a curved path, e.g. a quadrant. Thus, surfaces of the ends of the core of the electromagnet lie at an angle of, for example, 90° to one another. Other angles are also possible, e.g. up to approx. 140°. In particular, the pole pointing outwards to the periphery of the stator ring does not have to run parallel to the central axis of the stator ring. In such a case, however, the inside of the tubular section of the rotor should also be tilted relative to the axis of rotation, so that a largely constant gap is created between the pole face of the electromagnet and the magnets on the inside of the tubular section of the rotor ring. However, only the surfaces of the permanent magnets could be inclined.

Due to the large number of electromagnets, an effective control of the electromagnets is necessary in order to drive the rotor of the disc motor in the most effective way possible. Standard controls can be used for this. These can activate several—in particular selected ones—of the majority of the electromagnets of the stator ring at the same time. Typically, the electromagnets are electrically connected together within the stator ring such that only three external connections are required.

In addition, the electromagnets have windings, which, however, must follow the curvature of the curved core.

It is pointed out that features or components of different embodiments that are the same or at least functionally equivalent to the corresponding features or components of the embodiment are largely provided with the same reference symbols or with a different reference symbol, which differs only in its first Digit differs from the reference number of a (functionally) corresponding feature or a (functionally) corresponding component. To avoid unnecessary repetition, features or components that have already been explained using a previously described embodiment will not be explained in detail later.

Furthermore, it is pointed out that the embodiments described below only represent a limited selection of possible embodiment variants of the invention. In particular, it is possible to combine the features of individual embodiments with one another in a suitable manner, so that a large number of different embodiments can be regarded as obviously disclosed for the person skilled in the art with the embodiment variants explicitly presented here.

1 Figure 1 shows a basic form of disc motor with a rotor ring 116 and a stator ring 120 that are separate from each other. The rotor ring 102 has a first annular surface 102 and a parallel opposing second annular surface 106, each perpendicular to an imaginary axis of rotation through a center point 110 of the rotor ring, and a first plurality of permanent magnets 114 (not all permanent magnets are identified by the reference number) regularly arranged on a circular path in corresponding circle segments, which extend through the rotor ring 102 from the first surface 104 in the direction of the second surface 106, on. The permanent magnets 114 can reach up to the second surface 106 or can only be flush with the first surface. In this case, a north-south alignment of the permanent magnets 115 of the first plurality runs parallel to the imaginary axis of rotation, and adjacent permanent magnets 114 each have north-south alignments rotated by 180° with respect to one another. That is, their north-south direction alternates between adjacent permanent magnets 114 in each case.

Also attached to the rotor ring 102 is a first tube portion 116 extending from an outer periphery of the rotor ring 102 concentrically with the imaginary axis of rotation away from the first annular surface 102 (in 1 left to right). The tube section 116 has a second plurality of permanent magnets 118 arranged regularly on an inside of the first tube section 116 . It should also be noted that the reference numeral 116 is shown on an outer periphery of the tube section 116 and thus the rotor ring 102 .

The first plurality is equal in number to the second plurality; i.e. the number of permanent magnets 118 on the inside of the tube section 116 and those in the first surface 104 of the rotor ring 102 are identical and are located in pairs in the same segment of a circle.

For the permanent magnets 118, the north-south alignments of the permanent magnets 118 of the second plurality each run perpendicular to the imaginary axis of rotation and adjacent permanent magnets 118 of the second plurality each have north-south alignments rotated by 180° with respect to one another. Ie that the alignment gene of adjacent permanent magnets 118 alternate regularly. In addition, the respective different poles of the corresponding permanent magnets 114 of the first plurality and the second plurality (permanent magnets 118) in the respective circular segment are at an angle of, for example, 90° to one another.

In addition, the disc motor has the first stator ring 120 . This has a first annular surface 122 and a parallel opposite second annular surface (not shown), each of which extends perpendicularly to the imaginary axis of rotation through a center point 110 of the first stator ring 120 and the rotor 100, the imaginary axis of rotation of the first stator ring 120 and those of the rotor 100 are identical.

The stator 120 also has a third plurality of electromagnets (not directly visible here because they are inside the stator 120 ) within the first stator ring 120 . The third plurality is numerically smaller than the first plurality. This means that the number of electromagnets in the stator 120 is less than the number of permanent magnets in the surface 104 of the rotor ring 102 (or on the inside of the tube section 116; i.e. a ratio of 3:4 has proved to be practical, for example 21:28 However, other ratios are also possible.

The electromagnets have a curved core (e.g. 90° or an angle down to about 45°). One pole 126 of each electromagnet points toward an outer circumferential periphery 124 of the first stator ring 120 and a corresponding other pole 128 of each electromagnet points toward the first surface of the first stator ring 120 .

A first gap is thus located between the respective poles 126 of the electromagnets pointing to the periphery 124 of the stator ring 120 and the second plurality of permanent magnets 118 on the inside of the first tubular section 116 of the rotor 100 . A second gap exists between the poles of the electromagnets pointing toward the first surface 102 and the first plurality of permanent magnets 114 that is opposite a plane of the corresponding poles of the electromagnets such that the rotor 100 is free to rotate with respect to the stator ring 120 .

2 12 shows a sectional view 200 through a stator 120 having a curved electromagnet 202. Each of the electromagnets 202 has a curved core 204 and a corresponding winding surrounding it in a conventional manner. A respective pole 126 of the electromagnets 202 thus points in the direction of the outer periphery 124 of the stator ring 120 and thus in the direction of the permanent magnets 118 of the rotor when the rotor is slid over the stator. The other pole 128 of the electromagnets 202 then points in the direction of the permanent magnets 114 which are integrated into the first surface 104 of the rotor ring 102 .

The rotor ring can also have openings 208 in sections. These can ensure better internal ventilation of the disc motor and also ensure weight reduction with full functionality.

3 Figure 12 illustrates the assembled disc motor 300 made up of the rotor ring 100 and the stator/stator ring 120 as described above. In addition, electrical connections 302 can be seen, which are connected to the electromagnets in the usual way within the stator. The inner periphery 304 of the stator 120 may include a bearing (not shown) through which a hub may be slid, associated, for example, with a rim or other axle that may be driven by the rotor ring 100 by, for example, interlocking. In this way, a separate bearing for the rotor 100 is not necessary (weight saving).

4 represents a half section 400 through the assembled disc motor 300 acc. 3 The first gap 402 between one pole of the curved electromagnet 202 and the magnet 118 on the inside of the tubular section 116 of the rotor and the second gap 404 between the other pole of the electromagnet 202 and the permanent magnet 114 of the rotor disk 102 can be clearly seen .

5 12 shows the stator 120 together with a spacer tube section 502 which is fixedly connected to the stator/stator ring 120 concentrically to the central axis of the latter. For this purpose, the stator ring can be connected to threads in the bores 504 of the spacer tube section 502, for example by bores through the stator.

6 shows a combination of the two stators 120 and 602, which are connected to one another by the spacer tube section 502. The bore 604 can be used as a passage for a screw connection to the spacer tube section 502 . The spacer tube section 502 can also house the electrical leads for the stator 120 inside the spacer tube section 502 . Plug connections 506 can connect the respective stator 120, 602 to the lines inside the spacer tube section (eg via sockets).

The spacer tube section 502 extends between the electromagnets and an inner diameter of the first stator ring 120 concentrically away from the first surface of the stator ring.

The second stator ring 602 is concentrically attached to the spacer tube portion 502 parallel to the first stator ring 120 . The second stator ring 602 has a structure corresponding to the first stator ring 120 . The first surface of the first stator ring 120 faces the first surface 120 of the second stator ring 602 . The rotor ring lies between the two first surfaces of the two stators 102 and 602 (not yet shown here).

Additionally points - in 7 - now the expanded rotor 700 has a second tube section 702, which extends concentrically and symmetrically to the first tube section 116 from the second surface 106 of the rotor 100, and corresponding permanent magnets, with pole orientations of the permanent magnets on the inside of the first tube section and the inside of the second pipe section 702 can alternate in the respective same circle segment.

Here too there is a third gap between the respective poles of the electromagnets pointing towards the periphery of the second stator ring and the plurality of permanent magnets on the inside of the second tubular section of the rotor 100 . A fourth gap is located between the first surface facing poles of the second stator ring electromagnets and the first plurality of permanent magnets which is opposite a plane of the poles of the second stator ring electromagnets such that the rotor is free to rotate with respect to the stator ring.

This exemplary embodiment of the rotor is therefore constructed symmetrically to the rotor disk.

In this exemplary embodiment, the permanent magnets 114 should point from one surface of the rotor ring to the other. In addition, corresponding permanent magnets in the same circular segments of the first and the second tube section of the rotor 100 must have different poles, each pointing towards the center of the rotor 100 . Thus, alternating poles of the permanent magnets (114, cf. 1 ) of the rotor disc and permanent magnets (118, cf. 1 ) on inner sides of the respective pipe sections at the periphery of the rotor.

Although it is possible two identical rotors 100 according to 1 to be used with one rotor disk at a time, as shown; but it is also practical to use a common rotor disk through which the permanent magnets 114 are drawn from a surface 104 (cf. 1 ) of the rotor disk to the other (106, cf. 1 ) pass through.

8th shows an assembled disk motor 800 consisting of the double stator 600 according to FIG 6 in the middle and the extended rotor 700 according to 7 . Assembling the disk motor 800 follows as a logical sequence: (i) provide a stator with a spacer tube section, (ii) put the rotor on from one side, (iii) put on the second stator from the same side and connect the stator to the spacer tube section.

Again, the rotor can be held by an inside of a rim so that the required gaps are maintained and the rotor remains free to rotate. The practical grooves on the periphery of the rotor are not shown. Alternatively, the rotor may ride on a bearing on the spacer tube section

9 shows another half section 900 through the stators, the position of the curved electromagnets of the stators 120 and 602 and the two tube sections 116 and 702 of the rotor 100. The rotor of this embodiment, which here consists of two mutually symmetrical partial rotors, each consisting of the rotor ring and the associated pipe section with the corresponding permanent magnets, could be produced can also be produced in one piece in its basic structure. It would then consist of a rotor disk and a tube section that is twice as wide as an associated tube section and is firmly connected to the center of the rotor disk. In this case, the in 9 shown central wall 902 between the two partial rotors are omitted. In this way the center wall could be reduced in thickness to the thickness of a single rotor disc. In this case, only half of the permanent magnets in the rotor disk would be required for the rotor disk. These would extend from the first surface of the rotor disk to the second surface of the rotor disk. This would make further cost and weight savings possible.

It is obvious that this version of the disc motor presented is referred to as the in-rotating version, since the rotor rotates between the two part-stators. Here, too, the rotor can be centered via the hub and rim of a wheel.

An alternative design is described by external rotor elements, which is shown in the following figures. 10 shows two adjacent stators 120 and 602. The second stator ring 602 has an identical structure to the first stator 120. Both stator parts of the coupled stator 1000 are connected to each other via their respective second surfaces. Each of the two stators 120 and 602 has a plurality of curved electromagnets, which emerge on the one hand from the respective circumferential periphery and on the other hand from a respective outer side of the stators 120 and 602 lying against one another. Typically, the adjacent and peripheral poles of the electromagnets would each have the same poles. In the 10 Electromagnetic surfaces labeled "N" and "S" only represent a temporary state of two of the electromagnets, as they are switched on and off via a respective control circuit according to a predetermined scheme in order to rotate the respective rotor through magnetic attraction (or repulsion) between corresponding electromagnets and permanent magnets to rotate.

11 shows a view 1100 of an embodiment with a rotor part 100 of an external rotor 10 presented double stator 1000 is half covered by a rotor 100 in this figure. In 12 a second rotor part also covers the second stator part of the double stator 1000. The two part rotors are corresponding 1 constructed and can be firmly connected to each other. Alternatively, however, they can also be held centered by grooves or serrations running on the periphery through the inside of a rim surrounding them.

13 shows a half section 1300 through the exemplary embodiment of the disk motor with a rotor running on the outside, which consists of two partial rotors 100 . One can also clearly see two of the plurality of curved electromagnets 202 of double stator 1000, each acting on a pair of permanent magnets. One of the permanent magnets of the pair is located on one of the rotor disks and the associated other permanent magnet of the pair is located on the respective inside of the tubular section of the respective rotor part.

The rotor parts have an identical (mirror-symmetrical) structure, in which a peripheral end of the respective first tube section of the first rotor and the second rotor are firmly connected to one another, so that a resulting composite of the first rotor and the second rotor forms the first stator and the second stator in an outer area in which the first two pipe sections are connected to one another and enclose the stator ring in the area of its periphery.

14 and 15 show the example 1400 and 1500 of the inner rotor according to eg 9 air blades 1402 on the inside of the rotor, through which an efficient heat dissipation from the inside of the disc motor can be effected. As already described above, such air blades 1400 can also be integrated at other points of the rotor. Examples are the surfaces of the rotor rings 102 or the insides of the tube sections 116 and 702 of the respective rotor. In addition, air blades could also be attached to the outer periphery of the rotors.

16 shows an exemplary embodiment 1600 of a disk motor 1602, the rotor 1608 of which has an example of toothing 1604, 1606 on its outside. The peaks 1604 and valleys 1606 find their correspondence on an inside of a rim such that the rotor 1608 is centered by the rim.

17 17 shows an embodiment 1700 of the disc motor 1702 according to FIG 16 , which is installed in a rim 1704, in a half-section view. It can also be seen that the hub 1706 of the rim 1704 receives the disc motor 1702 in that the inner diameter of the stators - or the inner diameter of the disc motor 1702 - corresponds to the hub diameter of the rim 1704, so that the rim rotates in and around the disc motor 1702 can. It is not necessary for the rotor to rotate in its own bearing, but rather to be held freely rotating between the stators by the rim with which it is geared.

18 18 shows an embodiment 1800 of one disc motor 1802 belongs to two with a fastener 1806 and a separate caliper/disc combination. Here, too, the rim 1804 is shown, into which the disc motor 1802 is integrated. On the right side of 18 a brake disc 1810 with a brake caliper 1808 is shown symbolically. The hub of the fields 1804 can be connected to the left part of the brake disc in a conventionally threaded manner. In this way, the disc motor 1802 can be fixed inside the rim. Although disc motors with rotors located on the inside were shown in the last exemplary embodiments, disc motors with rotors running on the outside can be used just as well in accordance with the concept presented here.

19 shows an exemplary embodiment 1900 for a fastening element 1802 snapped into place on a brake caliper 1808. In this case, the rim 1804—or the hub of the rim (not shown)—is fixed to the brake disc (not shown). However, it is clearly visible that the fastening element 1802 snaps into a groove of the brake caliper 1808 and the stator is thus effectively prevented from rotating on the hub of the rim 1804. As an alternative to using the brake caliper as a counter bearing for the fastening element 1802, which is designed here as an angular fastening element, other components of a vehicle could also be used. The disk motor can also be supplied with the necessary electrical connections via the fastening element. These can be integrated directly into the fastening element (not shown).

The description of the various exemplary embodiments of the present invention has been presented for better understanding, but does not serve to directly limit the inventive idea to these exemplary embodiments. The person skilled in the art will discover further modifications and variations. The terminology used here was chosen in such a way that it best describes the basic principles of the exemplary embodiments and makes them easily accessible to the person skilled in the art.

The illustrated structures, materials, acts, and equivalents of all means and/or steps with associated functionality in the claims below are intended to employ any structure, materials, or acts as expressed by the claims.

In summary, the following can be stated: A disc motor is presented, which in its basic form consists of a stator and a rotor. Due to the curved shape of the electromagnets, whose two poles each act on permanent magnets of the rotor, a comparatively high torque density and efficiency can be generated at low cost and with a simple structure.

The possibility of designing the stators and rotors twice opens up the possibility of elegantly realizing a disc motor with a rotor running on the inside and a rotor running on the outside.

Reference List

100

rotor

102

rotor ring

104

first annular surface of the rotor ring

106

second annular surface of the rotor ring

108

imaginary axis of rotation

110

Focus

112

first plurality of permanent magnets

114

Permanent magnets with alternating North/South/North/South orientation

116

pipe section

118

second plurality of permanent magnets

120

stator

122

first annular surface of the stator

124

outer circumferential periphery of the stator

126

Pole of an electromagnet of the third plurality

128

other pole of the electromagnet of the third plurality

200

perspective half section of the stator

202

curved core of one of the electromagnets of the third plurality

204

curved core

206

winding

208

breakthrough

300

compound disc motor

302

electrical connections

304

inner periphery of the stator

400

Perspective half section through the assembled disc motor acc. 3

402

1st column

404

2nd column

500

Stator with spacer

502

spacer tube section

504

drilling

600

connected stators

602

second stator

604

drilling

700

extended rotor with second tube section

702

second pipe section

800

composite disk motor consisting of the double stator acc. 6 and according to the extended rotor 7

900

perspective half section through stators

902

Center wall between rotor disks

1000

coupled or double stator

1100

Double stator with single-sided rotor

1200

Disc motor with external rotor

1300

Half section through disc motor with external rotor

1400

Example of an internal rotor with air blades

1402

air scoops

1500

Example of an internal rotor with air blades

1600

example

1602

disc motors

1604

increase

1608

deepening

1700

example

1702

disc motors

1704

rim

1706

hub of the rim

1800

example

1802

disc motor

1804

rim

1806

fastener

1808

caliper

1810

brake disc

1900

example

QUOTES INCLUDED IN DESCRIPTION

This list of the documents cited by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Patent Literature Cited

• DE 102014111234 A1 [0003]

Claims (19)

An electric disc motor for operation in a wheel rim of a vehicle, comprising - Having a first rotor - a rotor ring comprising - a first annular surface and a parallel opposite second annular surface, each extending perpendicularly to an imaginary axis of rotation through a center point of the rotor ring, - a first plurality of permanent magnets regularly arranged on a circular path in corresponding circular segments, which extend through the rotor ring from the first surface in the direction of the second surface, with north-south alignments of the permanent magnets of the first plurality each running parallel to the imaginary axis of rotation and each adjacent ones of the permanent magnets have north-south orientations rotated by 180° with respect to one another, - A first tube section, which extends from an outer periphery of the rotor ring concentrically to the imaginary axis of rotation away from the first annular surface, having - a second plurality of permanent magnets regularly arranged on an inside of the first tube section, the first plurality being equal in number to the second plurality, wherein north-south alignments of the permanent magnets of the second plurality each run perpendicular to the imaginary axis of rotation and adjacent permanent magnets of the second plurality each have north-south alignments rotated by 180° with respect to one another, and wherein different poles of the corresponding permanent magnets of the first plurality and the second plurality lie at a predefined angle to one another in the respective circle segment, - a first stator ring comprising - a first annular surface and a parallel opposite second annular surface, each extending perpendicularly to the imaginary axis of rotation through a center point of the first stator ring and the rotor, the imaginary axes of rotation of the first stator ring and that of the rotor being identical, - a third plurality of electromagnets within the first stator ring, the third plurality being smaller in number than the first plurality, the electromagnets having a curved core, and a pole of a respective one of the electromagnets pointing towards an outer circumferential periphery of the first stator ring, and a corresponding other pole of the respective one of the electromagnets is directed towards the first surface of the first stator ring. wherein there is a first gap between the respective poles of the electromagnets and the second plurality of permanent magnets facing the periphery of the stator ring on the inside of the first tubular section of the rotor, and wherein there is a first gap between the poles of the electromagnets and the first plurality facing towards the first surface of permanent magnets facing a plane of the respective poles of the electromagnets, there is a second gap, so that the rotor is free to rotate with respect to the stator ring. The disc motor accordingly claim 1 , additionally comprising - a spacer tube section extending between the electromagnet and an inner diameter of the first stator ring concentrically away from the first surface of the stator ring, - a second stator ring concentrically attached to the spacer tube section parallel to the first stator ring, the second stator ring having a construction corresponding to the first stator ring, and wherein the first surface of the first stator ring faces the first surface of the second stator ring, with the rotor ring lying between the two first surfaces, - a second tube section which extends concentrically and symmetrically to the first tube section from the second surface of the rotor extends and has corresponding permanent magnets, with alternating pole orientations of the permanent magnets on the inside of the first pipe section and the inside of the second pipe section in the same circular segment, with between the to Periphery of the second stator ring pointing respective poles of the electromagnets and the plurality of permanent magnets on the inside of the second tubular section of the rotor is a third gap, and between the poles pointing towards the first surface of the electromagnets of the second stator ring and the first plurality of permanent magnets facing a plane of the poles of the electromagnets of the second stator ring, there is a fourth gap, so that the rotor is free to rotate with respect to the stator ring. The disc motor according to claim 1 or 2 , additionally comprising - a first rotary bearing on the outside of the spacer tube section for receiving an inside of the side of the rotor pointing towards the axis of rotation. The disc motor according to claim 1 additionally comprising a second stator ring, which has a structure identical to the first stator ring, the first and second stator rings being connected to one another via their second surfaces, a second rotor, which has a structure identical to that of the first rotor, with a peripheral end of each of the first tube sections of the first rotor and the second rotor being fixedly connected to one another, so that a resulting composite of the first rotor and the second rotor forms the first stator and the second stator in an outer area, in which the first two tube sections are connected to one another and in the area of the periphery of the stator rings, enclose them. The disc motor according to one of the preceding claims, wherein the rotor ring additionally has first air vanes on a surface of the rotor rings which faces the imaginary center point of the rotor ring. The disc motor of any preceding claim, wherein the rotor ring includes second air vanes adjacent to or between the permanent magnets of the first plurality and extending away from the first surface of the rotor ring within the first gap. The disc motor according to one of Claims 1 until 3 , 5 or 6 , additionally comprising - a second pivot bearing on the inside of the pipe section, the second pivot bearing being adapted to receive a hub rotatably mounted in the second pivot bearing. The disc motor of any preceding claim, wherein the third plurality is in the ratio of 3 to 4 to the first plurality. The disk motor according to any one of the preceding claims, wherein the first stator ring has electrical connections which are connected to respective selected ones of the electromagnets via electrical connections running within the first stator ring, such that every third of the electromagnets can be activated simultaneously. The disc motor according to one of claims 2 , 4 until 9 wherein the spacer tube section includes insulated vias selectively interconnecting electrical connections in the first stator ring and the second stator ring. The disc motor according to any one of the preceding claims, wherein the first and/or the second stator ring consists of aluminum, steel or carbon material in which the coils of the electromagnets and insulated electrical connections can be embedded. The disc motor according to any one of the preceding claims, additionally comprising - a fastener extending away from one of the surfaces of the stator ring, the outer point of contact with the stator ring being at a smaller distance from the axis of rotation than an inner diameter of a rotor ring, and the inner point of contact with the stator ring being at a greater distance from the axis of rotation than the inner one Diameter of a rotor ring, the fastening element being suitable for being connected to an element of a vehicle in a fixed or detachable manner. The disc motor of any preceding claim, wherein the fastener is adapted to engage a groove, lug or bore of a brake caliper, thereby preventing rotation of the stator or stators relative to the brake caliper. The disc motor of any preceding claim, wherein the fastener extends perpendicularly away from one of the surfaces of the stator ring. The disc motor according to one of Claims 1 4 to 6, 8, 9, 11 to 14 additionally comprising - a third pivot bearing on a side of the first rotor ring facing the axis of rotation, the third pivot bearing being adapted to receive a hub rotatably mounted in the third pivot bearing. The disc motor according to any one of the preceding claims, wherein the hub is a hub of a rim or wherein the hub is an axisymmetric extension of a brake disc oriented towards the stator. The disc motor according to any one of the preceding claims, wherein a radial surface of a respective first tube section has one or more grooves or lugs adapted to engage corresponding lugs and grooves of a rim inner surface. The disk motor according to any one of the preceding claims, wherein respective cores and/or coils of the respective electromagnets do not rise from the surfaces to which they abut. The disc motor according to one of Claims 12 until 18 , wherein the fastening element is adapted to receive electrical connections of the respective stator and to make them connectable to a vehicle.

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